Aluminized steel is

steel Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistant ty ...

that has been plated with

aluminium Aluminium (aluminum in American and Canadian English) is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one third that of steel. I ...

silicon Silicon is a chemical element with the symbol Si and atomic number 14. It is a hard, brittle crystalline solid with a blue-grey metallic luster, and is a tetravalent metalloid and semiconductor. It is a member of group 14 in the periodic tab ...

alloy An alloy is a mixture of chemical elements of which at least one is a metal. Unlike chemical compounds with metallic bases, an alloy will retain all the properties of a metal in the resulting material, such as electrical conductivity, ductility, ...

, in a process analogous to

hot-dip galvanizing Hot-dip galvanization is a form of galvanization. It is the process of coating iron and steel with zinc, which alloys with the surface of the base metal when immersing the metal in a bath of molten zinc at a temperature of around . When expose ...

. The steel workpiece is immersed in molten aluminum to produce a tight

metallic bond Metallic bonding is a type of chemical bonding that arises from the electrostatic attractive force between conduction electrons (in the form of an electron cloud of delocalized electrons) and positively charged metal ions. It may be descri ...

between the steel and coating. The product has a unique combination of properties possessed by neither steel alone nor aluminium alone. Aluminized steel is more resistant to corrosion than bare steel while retaining properties of steel, at temperature lower than the melting point of aluminum, . Common applications include heat exchangers in residential furnaces, commercial rooftop

HVAC Heating, ventilation, and air conditioning (HVAC) is the use of various technologies to control the temperature, humidity, and purity of the air in an enclosed space. Its goal is to provide thermal comfort and acceptable indoor air quality. HV ...

units, automotive

muffler A muffler (North American and Australian English) or silencer (British English) is a device for reducing the noise emitted by the exhaust of an internal combustion engine—especially a noise-deadening device forming part of the exhaust sys ...

s, ovens, kitchen ranges, water heaters, fireplaces, barbecue burners, and baking pans. Aluminized steel transfers heat more effectively than bare steel. It often serves where

galvanized steel Galvanization or galvanizing ( also spelled galvanisation or galvanising) is the process of applying a protective zinc coating to steel or iron, to prevent rusting. The most common method is hot-dip galvanizing, in which the parts are submerg ...

might have been used historically, without galvanized steel's drawbacks. Characteristics vary depending on the aluminum alloy used.

Types

; Type 1: Hot-dip coated with a thin layer of aluminium-silicon alloy. 5% to 11% added silicon promotes better adherence. It is intended principally for heat resisting applications and also for uses where corrosion resistance and heat are required. Possible end uses are mufflers, furnaces, ovens, ranges, heaters, water heaters, fireplaces, and baking pans. Aluminized steel can withstand with almost no change in the base material. But due to silicon content it develops black spot. Aluminized steel has slowly started to convert bakery trays which were previously made by galvanized or galvalume steel as it does not contain lead which is poisonous. Type 1 is also commonly found in industrial products. ; Type 2: Hot-dip coated with commercially pure aluminum. It is intended principally for applications requiring atmospheric corrosion resistance. Type 2 may ultimately be manufactured into corrugated roofing and siding, grain bins, drying ovens, and air-conditioner condenser housings.

Properties

The basic structure of aluminized steel is a thin aluminium oxide layer outside, then an intermetallic layer that is a mix of aluminium, silicon, and steel, and finally a steel core.Kee-Hyun, Kim. Van-Daele, Benny. Van-Tendeloo, Gusfaaf. and Jong-Kyu, Yoon. (2006). "Observations of Intermetallic Compound Formation of Hot Dip Aluminized steel". Materials Science Forum, 519-21(2), 1871-75.
/ref> Both Type 1 and Type 2 show excellent high reflectivity characteristics. At temperatures up to , aluminized steel reflects up to 80% of heat projected onto it. Aluminized steel has the ability to maintain its strength at temperatures up to . Although

stainless steel Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's corros ...

is the stronger of the two, aluminized steel has a greater

electrostatic Electrostatics is a branch of physics that studies electric charges at rest (static electricity). Since classical times, it has been known that some materials, such as amber, attract lightweight particles after rubbing. The Greek word for amber ...

surface, and can therefore reflect heat better. Aluminized steel is highly resistant to

corrosion Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...

because of the thin layers of aluminium and silicon, which keep the underlying steel from

oxidizing Redox (reduction–oxidation, , ) is a type of chemical reaction in which the oxidation states of substrate change. Oxidation is the loss of electrons or an increase in the oxidation state, while reduction is the gain of electrons or a d ...

. These thin layers also keep pit corrosion from occurring, especially during exposure to salts that affect most other metals. However, despite the good corrosion resistance of aluminized steel, if the aluminium layer is disrupted and the steel is exposed, then the steel may oxidize and corrosion may occur.

Consumption

In North America nearly 700,000 tons of aluminized steel are consumed annually. Some of the common products made from aluminized steel include water heaters, ranges, furnaces, space heaters and grills.

Processing

Aluminized steel can be made using a variety of processes, cladding, hot dipping, galvanic coating,

metallizing Metallizing is the general name for the technique of coating metal on the surface of objects. Metallic coatings may be decorative, protective or functional. Techniques for metallization started as early as mirror making. In 1835, Justus von Li ...

, and calorizing, but the most effective process is hot dipping. The process of hot dipping starts by cleaning the steel, then placing the steel in a bath of Al-11%Si at a temperature of 988K and shaken, then pulled out and air dried. The aluminium diffuses into the steel, creating an intermetallic layer above the steel base layer, but below the outside aluminum coating. The aluminium coating is oxidized to help protect the inner steel from corrosion and further aluminium diffusion.Deqing, Wang. and Ziyuan, Shi. (2003) "Formation of Al2O3 Layer on Steel". Journal of Materials Science Letters, 22(14), 1003-1006. The silicon is added to the aluminium bath to create a thinner layer of aluminium on the steel. The hot dipping process is cheaper and more effective to produce aluminized steel than any other process.Wang, Chaur. Jeng. Badaruddin, Mohd.. (2010) "The dependence of high temperature resistance of aluminized steel exposed to water-vapour oxidation". Surface and Coatings Technology, 205(5), 1200-1205.

Uses

Aluminized steel was developed for providing more structural durability and a high

yield strength In materials science and engineering, the yield point is the point on a stress-strain curve that indicates the limit of elastic behavior and the beginning of plastic behavior. Below the yield point, a material will deform elastically and wi ...

in highly corrosive environments. It maintains the strength of high-alloy steel, but is cheaper to produce than high-alloy steels and thus is a preferred material for manufacturing automobile and motorcycle exhaust gas systems. Al-Si coatings are used to protect

boron steel Boron steel refers to steel alloyed with a small amount of boron, usually less than 1%. The addition of boron to steel greatly increases the hardenability of the resulting alloy. Description Boron is added to steel as ferroboron (~12-24% B). As ...

when

hot pressing Hot pressing is a high-pressure, low-strain-rate powder metallurgy process for forming of a powder or powder compact at a temperature high enough to induce sintering and creep processes. This is achieved by the simultaneous application of heat a ...

References